EP4019394A1 - Elektrische schiffsantriebssysteme und verfahren zur steuerung - Google Patents

Elektrische schiffsantriebssysteme und verfahren zur steuerung Download PDF

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Publication number
EP4019394A1
EP4019394A1 EP21215496.7A EP21215496A EP4019394A1 EP 4019394 A1 EP4019394 A1 EP 4019394A1 EP 21215496 A EP21215496 A EP 21215496A EP 4019394 A1 EP4019394 A1 EP 4019394A1
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EP
European Patent Office
Prior art keywords
reduced operation
limit
motor
parameter
electric
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP21215496.7A
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English (en)
French (fr)
Inventor
Thomas S. Kirchhoff
Jason S. Arbuckle
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Brunswick Corp
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Brunswick Corp
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Publication of EP4019394A1 publication Critical patent/EP4019394A1/de
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
    • B63H—MARINE PROPULSION OR STEERING
    • B63H21/00—Use of propulsion power plant or units on vessels
    • B63H21/21—Control means for engine or transmission, specially adapted for use on marine vessels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
    • B63H—MARINE PROPULSION OR STEERING
    • B63H21/00—Use of propulsion power plant or units on vessels
    • B63H21/12—Use of propulsion power plant or units on vessels the vessels being motor-driven
    • B63H21/17—Use of propulsion power plant or units on vessels the vessels being motor-driven by electric motor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
    • B63H—MARINE PROPULSION OR STEERING
    • B63H21/00—Use of propulsion power plant or units on vessels
    • B63H21/21—Control means for engine or transmission, specially adapted for use on marine vessels
    • B63H2021/216—Control means for engine or transmission, specially adapted for use on marine vessels using electric control means

Definitions

  • the present disclosure generally relates to marine propulsions systems, and more particularly to electric marine propulsion systems having electric motors and methods for controlling the same.
  • Electric propulsion systems comprising an electric motor rotating a propeller are known.
  • on-board electric drive systems and outboard electric drive systems have been developed for propelling marine vessels.
  • Different power supply arrangements for powering electric propulsion systems are also known.
  • Such power storage systems include one or more batteries or banks of batteries, and or may include other storage devices such as one or more ultracapacitors, fuel cells, flow batteries, and or other devices capable of storing and outputting electric energy.
  • U.S. Patent No. 6,507,164 discloses a trolling motor having current based power management including: an electric motor; a motor controller having an output for providing voltage to the motor; and a current sensor for measuring the electrical current flowing through the motor.
  • the motor controller Upon determining that the trolling motor has been operating above its continuous duty limit for a predetermined period of time, the motor controller begins reducing the voltage output to the motor until reaching an acceptable output voltage.
  • the controller is operated in three distinct modes with three distinct sets of operating parameters, namely: a normal mode wherein the output is set to a commanded level; a current limit mode wherein the output is set to a safe, predetermined level; and a transitional mode wherein the output is incrementally changed from the predetermined level to the commanded level.
  • U.S. Patent No. 6,902,446 discloses a DC motor having a motor housing and a motor controller housed within the motor housing.
  • the heat producing components of the motor controller are in thermal communication with the housing such that the majority of the heat produced by such components will be readily conducted to the environment in which the motor is operating.
  • the motor housing of the present invention When incorporated into a trolling motor, the motor housing of the present invention will be submerged so that controller produced heat will be dissipated into the water in which the trolling motor is operated.
  • U.S. Patent No. 7,385,365 discloses a method for error detection of a brushless electric motor, where at least one first motor parameter is measured or determined, and a second, estimated motor parameter is estimated on the basis of the first motor parameter. The second, estimated motor parameter is compared to a second, measured or determined motor parameter. An error of the electric motor can be found out according to the comparison.
  • U.S. Patent No. 10,723,430 discloses a propeller propulsion system for a watercraft that includes at least one electric motor and a propeller which can be driven by the electric motor.
  • the propeller is a surface piercing propeller.
  • the propulsion system includes a box-like body having a side wall on which the electric motor is fixed and a cover part on which an outdrive of the surface piercing propeller is applied.
  • the side wall and the cover part include holes through which a shaft of the motor and a shaft of the outdrive respectively pass.
  • the box-like body includes means for transmission of motion from the drive shaft to the outdrive shaft, and the propulsion system includes means for fixing the box-like body to a transom of the watercraft.
  • a method of controlling an electric marine propulsion system configured to propel a marine vessel includes measuring at least one parameter of an electric motor in the electric marine propulsion system and determining that the parameter measurement indicates an abnormality in the electric marine propulsion system.
  • a reduced operation limit is then determined based on the at least one parameter measurement, wherein the reduced operation limit includes at least one of a torque limit, an RPM limit, a current limit, and a power limit.
  • the electric motor is then controlled such that the reduced operation limit is not exceeded.
  • determining that the parameter measurement indicates an abnormality in the electric marine propulsion system includes determining that the parameter measurement is outside of a threshold range.
  • determining the reduced operation limit includes utilizing a lookup table providing reduced operation limits corresponding to various parameter values within a range of potential values for the at least one parameter.
  • the lookup table provides reduced operation limits indexed based on various parameter values for each of at least two parameters, and the reduced operation limit is calculated based on at least two parameter measurements utilizing the two-dimensional lookup table.
  • an electric marine propulsion system includes an electric motor driving a propeller into rotation and configured to propel a marine vessel.
  • a power storage device is configured to power the electric motor and one or more sensors are configured to measure a parameter of the electric marine propulsion system, including at least one of a motor temperature sensor configured to sense a temperature of the electric motor, a battery temperature sensor configured to sense a temperature within the power storage device, a current sensor configured to sense an input current supply to the electric motor, a voltage sensor configured to sense an input voltage supply to the electric motor, a motor speed sensor configured to sense a rotational speed of the electric motor, and a propeller speed sensor configured to sense a rotational speed of the propeller.
  • a control system is configured to determine that the at least one measured parameter of the electric marine propulsion system is outside of a threshold range indicating an abnormality.
  • a reduced operation limit is then determined based on the at least one parameter, wherein the reduced operation limit includes at least one of a torque limit, an RPM limit, a current limit, and a power limit.
  • the electric motor is then controlled such that the reduced operation limit is not exceeded.
  • the inventors have developed the disclosed system and method for electric marine propulsion control where one or more parameters of the electric marine propulsion system are monitored and one or more reduced operation limits are determined based on the monitored parameters in order to prevent short-term catastrophic failure of the electric motor and or other aspects of the electric marine propulsion system.
  • the system is configured to enable the operator to continue at least low speed propulsion of the marine vessel to facilitate their return to safety.
  • Catastrophic failure is where the propulsion system no longer operates to propel the marine vessel, such as to propel a marine vessel in a direction instructed by an operator via a steering input or by an automated guidance system controlling a direction of the marine vessel.
  • Short-term catastrophic failure is where such total failure of the propulsion system operation occurs immediately, or within minutes, or within the current operation session by the operator.
  • the system determines a reduced operation limit calibrated to enable continued operation of the propulsion system to propel the marine vessel to shore or to a starting point of the operator's trip, or to a home destination where a marine vessel is typically stored.
  • the reduced operation limit may be calibrated to enable continued operation of the propulsion system for several miles or several hours to return an operator to safety for a majority of boating applications.
  • the reduced operation limits may be calibrated to enable an operator to continue indefinite use of the propulsion system under the current measured conditions.
  • a reduced operation limit includes at least one of a torque limit, an RPM limit, a current limit, a power limit.
  • the torque limit limits an output torque of the electric motor 4.
  • the RPM limit limits the rotational speed of the electric motor 4, or alternatively the rotational speed of the propeller 8.
  • the current limit limits a current supplied to the electric motor 4.
  • a power limit limits the total power supplied to the electric motor, which may be effectuated as a current limit and/or a voltage limit.
  • the reduced operation limit may specifically include a voltage limit in addition to or as an alternative to a power limit or current limit.
  • FIG. 1 depicts an exemplary embodiment of a marine vessel 1 having an electric marine propulsion system 2 configured to propel the marine vessel in a direction instructed by an operator via a steering control system, or by a guidance system configured to automatically control steering of the marine vessel to steer the vessel toward a predetermined location or global position.
  • the electric propulsion system 2 includes an electric marine drive 3 having an electric motor 4 configured to propel the marine vessel 1 by rotating a propeller 10, as well as a power storage system 16, a control system 11, and a user interface system 35.
  • the motor 4 may be, for example, a brushless electric motor, such as a brushless DC motor.
  • the electric motor may be a DC brushed motor, an AC brushless motor, a direct drive, a permanent magnet synchronous motor, an induction motor, or any other device that converts electric power to rotational motion.
  • the electric motor 4 includes a rotor and a stator, as is well known in the relevant art.
  • the electric motor 4 is electrically connected to and powered by a power storage device 16.
  • the power storage device 16 stores energy for powering the electric motor 4 and is rechargeable, such as by connection to shore power when the electric motor 4 is not in use.
  • Various power storage devices and systems are known in the relevant art.
  • the power storage device 16 may be a battery system including one or more batteries or banks of batteries. In other embodiments, the power storage device 16 may include one or more fuel cells, flow batteries, ultracapacitors, and/or other devices capable of storing and outputting electric energy.
  • the power storage device 16 may further include a battery controller 20 configured to monitor and/or control aspects of the power storage device 16.
  • the battery controller 20 may receive inputs from one or more sensors within the power storage device 16, such as a temperature sensor 21 configured to sense a temperature within a housing of the power storage device where one or more batteries or other storage elements are located.
  • the battery controller 20 may further be configured to receive information from current, voltage, and/or other sensors within the power storage device 16, such as to receive information about the voltage, current, and temperature of each battery cell within the power storage device 16.
  • the battery controller 20 may be configured to calculate a state of charge of the power storage device 16, a state of health of the power storage device 16, a temperature of the power storage device, etc.
  • the electric motor 4 is operably connected to the propeller 10 and configured to rotate the propeller 10.
  • the propeller 10 may include one or more propellers, impellers, or other propulsor devices and that the term "propeller” may be used to refer to all such devices.
  • the electric motor 4 may be connected and configured to rotate the propeller 10 through a gear system 7 or a transmission.
  • the gear system 7 translates rotation of the motor output shaft 5 to the propeller shaft 8 to adjust conversion of the rotation and/or to disconnect the propeller shaft 8 from the drive shaft 5, as is sometimes referred to in the art as a "neutral" position where rotation of the drive shaft 5 is not translated to the propeller shaft 8.
  • Various gear systems 7, or transmissions, are well known in the relevant art.
  • the electric motor 4 may directly connect to the propeller shaft 8 such that rotation of the drive shaft 5 is directly transmitted to the propeller shaft 8 at a constant and fixed ratio.
  • Each electric motor 4 may be associated with a motor controller 14 configured to control power to the electric motor, such as to the stator winding thereof.
  • the motor controller 14 is configured to control the function and output of the electric motor 4, such as controlling the torque outputted by the motor, the rotational speed of the motor 4, as well as the input current, voltage, and power supplied to and utilized by the motor 4.
  • the motor controller 14 controls the current delivered to the stator windings via the leads 15, which input electrical energy to the electric motor to induce and control rotation of the rotor.
  • Sensors may be configured to sense the power, including the current and voltage, delivered to the motor 4.
  • a voltage sensor 29 may be configured to sense the input voltage to the motor 4 and a current sensor 28 may be configured to measure input current to the motor 4. Accordingly, power delivered to the motor 4 can be calculated and such value can be used for monitoring and controlling the electric propulsion system 2, including for monitoring and controlling the motor 4.
  • the current sensor 28 and voltage sensor 29 may be communicatively connected to the motor controller 14 in order to provide measurement of the voltage supplied to the motor and current supplied to the motor for thereto.
  • the motor controller 14 is configured to provide appropriate current and or voltage to meet the demand for controlling the motor 4.
  • a demand input may be received at the motor controller 14 from the central controller 12, such as based on an operator demand at a helm input device, such as the throttle lever 38.
  • the motor controller 14, voltage sensor 29, and current sensor 28 may be integrated into a housing of the electric motor 4, in other embodiments the motor controller 14 may be separately housed.
  • the electric motor 4 may include means for measuring and or determining the torque, rotation speed (motor speed), current, voltage, temperature, vibration, or any other parameter.
  • the electric motor 4 includes a temperature sensor 23 configured to sense a temperature of the motor 4, a speed sensor 24 configured to measure a rotational speed of the motor 4, and a torque sensor 25 for measuring the torque output of the motor 4.
  • An accelerometer 32 may be configured to measure vibration of the motor 4 or of the electric drive 3 more generally.
  • a propeller speed sensor 26 may be configured to measure a rotational speed of the propeller 10.
  • the propeller speed sensor 26 and/or the motor speed sensor 24 may be a Hall Effect sensor or other rotation sensor, such as using capacitive or inductive measuring techniques.
  • one or more of the parameters, such as the speed, torque, or power may be calculated based on other measured parameters or characteristics.
  • the torque may be calculated based on power characteristics in relation to the rotation speed of the electric motor, for example.
  • the various parameters of the electric propulsion system are utilized for detection of an abnormality and determining a reduced operation limit appropriate for enabling continued operation of the electric propulsion system 2 to prevent short-term catastrophic failure of the electric motor and enable the operator to continue at least low speed propulsion of the marine vessel in order to return to shore or otherwise reach safety.
  • the parameters may include one or more of the temperature of the electric motor, the temperature within the power storage device, the current amount supplied to the electric motor, the voltage supplied to the electric motor, the rotational speed of the electric motor, the torque supplied by the electric motor, and the rotational speed of the propeller 10.
  • a reduced operation limit is calculated.
  • the reduced operation limit may be calculated or determined based on one parameter or based on a plurality parameters of the electric marine propulsion system. For example, when one of the plurality of parameters being monitored exceeds a respective threshold indicating an abnormality, the reduced operation limit may be determined based on two or more of the plurality of parameters even if all such parameters have not exceeded the threshold.
  • a reduced operation limit may be determined based on the measured temperature in combination with one or more other parameters, such as based on temperature and input current and/or temperature and torque output.
  • Various examples of the reduced operation limit determination are provided herein.
  • the reduced operation limit determination may be performed by the control system 11, such as by the central controller 12.
  • the electric propulsion system 2 may include a plurality of controllers communicatively connected and configured to cooperate to provide the method of controlling the electric marine propulsion system described herein.
  • the motor controller 14, battery controller 20, and central controller 12 and may cooperate as a distributed control system 11 to effectuate control of the marine propulsion system as described herein such that the reduced operation limit is not exceeded and catastrophic failure of the electric motor is delayed or prevented.
  • a person of ordinary skill in the art will understand in view of the present disclosure that other control arrangements are available and that the control functions described herein may be combined into a single controller or divided into any number of a plurality of distributed controllers that are communicatively connected.
  • various sensing devices 21, 23-25, 26, and 28-29 may be configured to communicate with a local controller, such as the motor controller 14 or battery controller 20, and in other embodiments the sensors 21, 23-25, 26, and 28-29 may communicate with the central controller 12 and one or more of the motor controller 14 and or battery controller 20 may be eliminated.
  • Controllers 12, 14, 20 (and or the sensors) may be configured to communicate via a communication bus such as a CAN bus or a LIN bus, or by single dedicated communication links between controllers 12, 14, 20.
  • Each controller may comprise a processor and a storage device, or memory, configured to store software and/or data utilized for controlling and or tracking operation of the electric propulsion system 2.
  • the memory may include volatile and/or non-volatile systems and may include removable and/or non-removable media implemented in any method or technology for storage of information.
  • the storage media may include non-transitory and/or transitory storage media, including random access memory, read only memory, or any other medium which can be used to store information and be accessed by an instruction execution system, for example.
  • An input/output (I/O) system provides communication between the control system 11 and peripheral devices.
  • FIG. 2 depicts another embodiment of an electric marine propulsion system 2.
  • the electric marine propulsion system 2 includes an outboard marine drive 3 having an electric motor 4 housed therein, such as housed within the cowl 50 of the outboard marine drive.
  • the marine propulsion system 2 may include other types of electric marine drives, such as inboard drives or stern drives.
  • the electric marine drive 3 is powered by the scalable storage device 16 including a bank of batteries 18.
  • the central controller 12 which in the depicted embodiment is a propulsion control module (PCM), communicates with the motor controller 14 via communication link 34, such as a CAN bus.
  • the controller also receives input from and/or communicates with one or more user interface devices in the user interface system 35 via the communication link, which in some embodiments may be the same communication link as utilized for communication between the controllers 12, 14, 20 or may be a separate communication link.
  • the user interface devices in the exemplary embodiment include a throttle lever 38 and a display 40.
  • the display 40 may be, for example, part of an onboard management system, such as the VesselView TM by Mercury Marine of Fond du Lac, Wisconsin.
  • the user interface system 35 may also include a steering wheel 36, which in some embodiments may also communicate with the controller 12 in order to effectuate steering control over the marine drive 3, which is well-known and typically referred to as steer-by-wire arrangements.
  • the steering wheel 36 is a manual steer arrangement where the steering wheel 36 is connected to a steering actuator that steers the marine drive 3 by a steering cable 37.
  • FIG. 3 depicts one embodiment of a method 100 of controlling an electric marine propulsion system 2 to effectuate reduced operation and prevent catastrophic failure in the event of an abnormality detection within the system 2.
  • One or more parameters of the electric propulsion system are measured at step 102.
  • one or more of the plurality of parameters of the electric propulsion system may be measured, such as motor temperature, battery temperature, current supplied to the electric motor, voltage supplied to the electric motor, rotational speed of the electric motor, torque of the electric motor, and a rotational speed of the propeller.
  • Each of the one or more parameters being measured is compared to a respective threshold range indicating proper operation at step 104.
  • the thresholds for each parameter are calibrated to account for various normal operating conditions. Thus, when one or more parameter measurements exceeds a respective threshold, then an abnormality is indicated as to the function of the electric marine propulsion system 2.
  • the thresholds are, however, sufficiently less than or before a failure threshold where operation of one or more elements in the propulsion system 2 ceases.
  • the threshold ranges implemented in the disclosed control system may be significantly less than or occur before any error threshold at which the electric motor 4 would shut down and or before the power storage system would be disconnected so as to cease supplying power to the electric motor 4. Accordingly, the thresholds may be calibrated for early detection of a problem or abnormality before damage to the motor 4 or other system occurs and where intervention and reduced operation, such as reduced current and/or speed, can prevent further damage to the system 2 or at least delay catastrophic failure.
  • a reduced operation limit is then determined at step 108.
  • the reduced operation limit may be determined based on the at least one parameter measurement that exceeded the respective threshold, and in some embodiments may be calculated based on two or more parameter measurements.
  • the reduced operation limits may be calibrated to prevent further increase in the relevant parameters value(s), or otherwise to prevent the detected abnormality from increasing beyond the relevant threshold.
  • the reduced operation limit may be calibrated or otherwise determined to prevent an increase in the difference between the parameter measurement and the relevant threshold.
  • the reduced operation limit decreases as a difference between the parameter measurement and the threshold increases.
  • the limit imposed by the reduced operation limit becomes more restrictive and further reduces operation of the electric propulsion system as the parameter measurement moves further outside the bounds of normal operation.
  • the reduced operation limit is one of a torque limit, an RM limit, a current limit, or a power limit
  • the limit value decreases as the parameter measurement gets further outside of the normal range.
  • the reduced operation limit is determined by accessing a look-up table providing reduced operation limits corresponding to various possible values for a given parameter. Exemplary look-up tables are provided herein, which in various embodiments may provide reduced operation limits or limits, based on one or a plurality of parameter measurements.
  • the limits can be calibrated to allow a maximum amount of propulsion authority and ability to an operator while still preventing catastrophic failure.
  • the operator may experience only a minor difference in operation and may be permitted to get the vessel on plane or otherwise operate the vessel normally except avoiding the highest speed operation.
  • the parameter measurement abnormality may require more drastic limits, such as where a current limit within the motor is significantly and/or continually exceeded.
  • the reduced operation limit may be calibrated to minimize further damaging the motor as much as possible in order to delay catastrophic failure of the motor or other element in the propulsion system 2 as long as possible.
  • the electric motor 4 and/or power distribution thereto is then controlled at step 110 such that the reduced operation limit is not exceeded.
  • operator authority over propulsion may be granted up to the relevant limit set by the reduced operation limit. As described above, this may prevent the operator to operate the marine vessel normally at certain speeds below the maximum and, in some embodiments, may even permit the operator to get the vessel on plane and thus get home more quickly.
  • the reduced operation limit may be maintained until an unlatch condition has occurred.
  • the unlatch condition may be different depending on the exceeding parameter or detected abnormality.
  • the unlatch condition may be moving a throttle lever or other operator input device to a neutral, or zero speed, position.
  • the unlatch condition may be power cycling the propulsion system, such as turning the propulsion system off and then back on.
  • the unlatch condition may be based on the parameter measurement, such as maintenance of a parameter measurement below the threshold or below a different unlatch threshold that is lower than the normal threshold, for a period of time.
  • the system may include an accelerometer 32 to sense vibration, such as vibration caused by the motor 4. Excess vibration may be an indicator of a mechanical malfunction within the motor, such as a failed bearing or a jammed propeller.
  • the accelerometer 32 is configured, for example, to measure a frequency and magnitude of vibration, such as in hertz and meters per second squared (m/s 2 ).
  • the frequency and/or the magnitude of vibration may be utilized and compared to one or more thresholds to identify an abnormality triggering a reduced operation limit.
  • the reduced operation limit may take the form of an RPM limit to limit the rotational speed of the electric motor.
  • FIGS. 4A and 4B depict current over time delivered to an electric motor.
  • a corresponding power limit is also shown in both scenarios at FIGS. 4A and 4B.
  • FIG. 4A depicts an exemplary current and power limit relationship in a motor over current scenario where no reduced operation limit is imposed and the current increases over time and exceeds a threshold that trips a fault condition that ceases operation of the motor, such as by tripping a breaker that eliminates all power to the motor.
  • Line 52 illustrates the current over time which increases to 40 amps at time point 55. In the depicted example, the current rating for the motor is set at 40 amps. The current increases beyond the failure setpoint and pops a breaker at time 55, causing the available power to go to zero.
  • Line 54 represents the available power limit or power authority granted to an operator. 100% authority is granted to the operator to demand full output and function from the motor until the current limit is exceeded at time 55 triggering the fault, at which point the available power goes to zero and the motor no longer operates at all.
  • FIG. 4B depicts current and power limit as a function of time where an embodiment of the disclosed control method is utilized such that a reduced operation limit is imposed prior to triggering the fault condition, or failure point, by exceeding the 40 amp breaker limit.
  • the current increases over time as represented by line 58 triggering sequential reductions in the reduced operation limit, which is exemplified here as a power limit, in reaction to the increasing current.
  • Line 56 represents the current input to the motor 4 over time.
  • a first threshold is exceeded, where the current threshold is less than the 40 amp failure point.
  • the first threshold may be 37 amps, where the maximum available power to the motor is limited once the current reaches 37 amps.
  • a reduced operation limit of 90% maximum available power is implemented the current reaches the 37 amp threshold at time 59.
  • the system 2 may be configured such that once the reduced operation limit is implemented, full propulsion authority is not returned to the operator unless an unlatch condition occurs. Exemplary unlatch conditions are described above with respect to FIG. 3 . Thus, as operation limits may be further reduced over time, the operation limits will not increase to grant authority back to the operator unless the unlatch condition has occurred.
  • FIGS. 5A-5F depict exemplary lookup tables providing reduced operation limits corresponding to various parameter values within a range of potential values for each respective parameter being monitored. While certain examples are provided in the Figures, a person of ordinary skill in the art will understand in view of the present disclosure that other parameters may be monitored and reduced operation limits imposed based on the monitored parameter in accordance with present disclosure.
  • FIG. 5A illustrates an exemplary table providing reduced operation limits indexed based on motor temperature in degrees Celsius (°C).
  • the reduced operation limits are implemented where either the motor is too cold or the motor is too hot.
  • the reduced operation limit on a low temperature motor prevents damage to the motor being operated when it is too cold, and thus not well lubricated.
  • the reduced operation limit on a high temperature motor prevents or limits overheating.
  • a power limit is implemented where the motor temperature is outside of (either below or above) the normal temperature range for an operating motor.
  • the normal operating temperature range where full authority is granted for an operator to operate the motor to its maximum is between 10 °C and 110 °C.
  • a reduced operation limit is implemented.
  • interpolation may be used based on the motor temperature (or any parameter in the table) in order to calculate the reduced operation limit based on the table, which in the depicted example is a power limit as a percent of the maximum rated power for the motor 4.
  • a power limit percent is calculated to be between 75% and 100%.
  • the power limit percent is calculated to be between 50% and 75%, interpolating between the values. Similar steps are provided when the motor temperature exceeds 110 °C, where a reduced operation limit is again imposed to prevent damage to the motor from overheating.
  • a second high temperature threshold is exceeded and further reduced operation limits are implemented.
  • a reduced operation limit of 10% input power limit is effectuated which greatly reduces the output and function of the electric motor 4 but maintains at least some degree of functionality so as to continue low speed propulsion.
  • FIG. 5B exemplifies a lookup table providing reduced operation limits corresponding to input current to the motor.
  • This table corresponds to the example provided at FIG. 4B , where a reduced operation limit is implemented to prevent the current from exceeding the 40 amp threshold that will trip the breaker.
  • the reduced operation limit is implemented once the input current reached 37 amps.
  • a maximum reduced operation limit of 10% is implemented once the current approaches 40 amps. Beyond 40 amps, the system will not further reduce operation to further the goal of maintaining at least minimal output to support continued low speed propulsion for as long as possible. Thus, above the 40 amp failure threshold, the reduced operation limit remains at 10%.
  • the disclosed method will not cease propulsion output, but only limits the operation as necessary to extend at least low speed propulsion for as long as possible.
  • FIG. 5C exemplifies a lookup table providing reduced operation limits corresponding to battery temperature in degrees Celsius.
  • the power storage device 16 may have an associated temperature sensor 21 to measure a temperature associated with the one or more batteries or other storage elements within the power storage device 16. If the battery temperature, such as measured by any temperature sensor 21 associated with any battery, exceeds a temperature threshold indicating high battery temperature, then a reduced operation limit is imposed.
  • the reduced operation limit becomes more restrictive as the battery temperature increases.
  • the reduced operation limit becomes more restrictive.
  • the difference may be a magnitude difference between the parameter value and the closest one of the high or low threshold defining the threshold range.
  • FIG. 5D depicts an exemplary table providing reduced operation limits corresponding to motor input voltage, where reduced operation limits are imposed where the input voltage to the motor is above or below the normal voltage range, which in the depicted example is 46-52 volts. This would apply, for example, to a 48 volt system such as that depicted in FIG. 2 . Where the motor input voltage is below that normal range, and thus below the threshold of 46 volts, then an undervoltage scenario has occurred and an output limit restriction is imposed that increasingly restricts the power limit for the motor as the undervoltage condition becomes more severe. In this example, a maximum power limit of 10% of the total normal power limit may be implemented when the motor voltage reaches a low of 31 volts or a high of 56 volts.
  • a power limit between 10% and 100% is calculated in an undervoltage or overvoltage scenario where the motor input voltage is outside of the normal range of 46 to 52 volts but within the range of 31 to 56 volts.
  • Such a reduced operation limit is calculated based on the motor input voltage parameter measurement by interpolating the table values, as described above.
  • FIG. 5E depicts reduced power limits corresponding to various motor speed values so as to protect against both over and under speed.
  • normal motor speed range is defined as rotation speeds between 100 and 3000 revolutions per minute (rpm). Any rotational speed measured below or above that range is considered an indicator of abnormal operation and induces a reduced operation limit, which in this example again is a power limit that limits the available power to the operator to a defined percentage of the maximum rated available power for the motor 4 under normal operating conditions.
  • the reduced operation limit may be implemented by controlling one or more other parameters of the motor, such as by controlling torque output of the motor 4, by controlling rotational speed of the motor, or by specifically limiting current rather than available power.
  • FIG. 5F depicts an example where rotational speed of the motor is limited based on sensed vibration of the motor 4.
  • vibration magnitude measured by the accelerometer 32 may be monitored to detect that the vibration is within an expected range.
  • High vibration may indicate a mechanical abnormality within the motor 4 or the propeller 10.
  • Vibration magnitude may be measured, for example, as a g-force.
  • a normal threshold which is exemplified here as 0.35 g
  • a reduced operation limit is implemented to reduce the rotational speed of the motor 4.
  • the vibration magnitude increases beyond that threshold, the reduced operation limit increases at an increasing rate so as to prevent catastrophic failure caused by the mechanical issue.
  • the operation limit becomes significantly more restrictive.
  • the operation limit is a 10% RPM limit (meaning that the maximum permitted RPM of the motor is 10% of the normal maximum RPM limit permitted under normal operating conditions).
  • the reduced operation limit determination may occur, for example, at the central controller 12 and be communicated to the motor controller 14 for implementation.
  • the reduced operation limit may be communicated from the central controller 12 to the motor controller 14 via CAN bus or by some other communication link.
  • the central controller 12 may store one or more lookup tables, such as those exemplified herein, providing reduced operation limits based on parameter values and enabling calculation of a reduced operation limit based on a specific measure parameter as described in the examples illustrated at FIGS 5A-5F .
  • reduced operation limits can be calculated on two or more parameter measurements.
  • lookup tables providing reduced operation limits indexed based on two parameter values may be provided and two-dimensional table.
  • a three-dimensional table may provide reduced operation limits indexed based on three parameters.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • Ocean & Marine Engineering (AREA)
  • Control Of Electric Motors In General (AREA)
EP21215496.7A 2020-12-22 2021-12-17 Elektrische schiffsantriebssysteme und verfahren zur steuerung Pending EP4019394A1 (de)

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